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www.seipub.org/fwr Friction and Wear Research Volume 2, 2014 22
 
Contact Characteristics of Metallic Materials in Conditions of Heavy Loading by Friction or by Electric Current
Marina I.Aleutdinova
*1, 2
 , Viktor V. Fadin
1
 , Aleksandr V. Kolubaev
1, 3
 , Valery A. Aleutdinova
4
1
Institute of Strength Physics and Materials Science of Siberian Branch Russian Academy of Sciences,
2
Seversk Technological Institute - branch of State Autonomous Educational Institution of Higher Professional Education «National Research Nuclear University «MEPhl»
3
 
National Research Tomsk Polytechnic University
 4
National Research University Saint Petersburg State Polytechnical University 2/4 pr. Akademicheskii, Tomsk, 634021, Russia
*1
aleut@ispms.ru
 
Received 5 September 2013; Accepted 23 October 2013; Published 15 May 2014 © 2014 Science and Engineering Publishing Company
 Abstract
Friction of composites having composition TiC+metal was realized at pressure more 100 MPa in lubricant medium. Sliding electric contact of metal materials was carried out at contact current density higher 100 A/cm
2
 without lubricant. It was shown that these loading parameters cause a friction surface wear which increases at increasing alloying atoms quantity or number of phases in the initial structure of material.
Keywords
Composite; Initial Composite Structure; Wear; Contact Conductance
 
Introduction
Contact interaction occurs mostly in contact spots. Microvolumes of contact spots undergo large plastic deformation and transit to other structural state. Processes (plastic deformation, formation of chemical compounds, etc) in contact zone could percolate into depth more than 20 microns below the surface . As a result, a layer of friction induced structures is being formed and these structures define basic contact characteristics – wear resistance and friction coefficient. High wear resistance occurs when contact layer structure becomes stable in friction process (Fedorchenko, 1980). Therefore it is necessary to exclude, in the first turn, the plastic deformation in contact spots. It is often being achieved by raising the material's yield point, or to be more specific, by increasing the hardness of the initial material structure. As a rule, hardnening leads to decreasing the ductility. Therefore this way may be effective in the absence of structural changes in contact layer during the process of friction. Materials oriented for friction under high pressure must have high structural strength and high hardness of initial structure. Composites based on the titanium carbide could be used as such materials. It is of scientific interest to produce these materials by selfpropagating hightemperature synthesis (SHS), for example, by pressing exothermic powder mixture in combustion wave (Merzhanov, 1995) and then define their performance in friction under pressure above 20 MPa. In addition, it could be interesting to study resources of materials under higher heat flow through contact spots, which might be realized by transmitting electric current through the worn surface. Sintered composites produced by methods of powder metallurgy are used in such friction conditions. Commercial composites can realize satisfactory wear resistance at contact current density lower than 60 A/cm
2
 during sliding current collection (Braunovic, 2007). Friction at pressure higher 20 MPa or sliding at contact current density above 60 A/cm
2
 may be assumed to be the heavy work conditions. Initial structure of friction pair materials is one of main
 
Friction and Wear Research Volume 2, 2014 www.seipub.org/fwr 23
 
factors which can provide effective work of friction units in these conditions. The objective of the present research is to get some idea about interconnection of contact characteristics and initial structure of composites obtained by SHS methods and powder metallurgy, under friction loading with rated pressure higher 20 MPa or current loading with contact current density higher 100 A/cm
2
.
Materials and Experimental Metods
Sample Preparation
The materials of exothermic charge for obtaining model microheterogeneous SHS-composites were powders as follows: titanium, lamp soot, iron (98%Fe+ admixtures), Hadfield steel (HS, 13%Mn). The SHS-composites had the phase compositions presented in Tables 1 and 2. They were fabricated in a closed mold mounted in the working space of a hydraulic press. Combustion was initiated by high-voltage discharge after heating to 773 K. The powder charge was placed under the pressure up to 70 MPa during combustion process. Macroheterogeneous composites (Table 3) were fabricated by granulation of SHS-composite TiC+10%Cu+25%HS in grinder-mill to grain size 0,4-1,0 mm, then by mixing them with iron and saturating this mixture with bronze (Cu+8%Sn+12%Pb) in proportions specified in Table 3.
Testing Metods
The hardness
HV
was measured by the Vickers hardness tester. The bending strength
σ
 was determined on an Instron-1185 testing machine. The lattice parameter
a
 was found using a DRON-3 X-ray diffractometer in cobalt radiation. The thermal conductivity
λ
0
 of the composites was determined by comparing it to the thermal conductivity of the aluminium (which was used as a reference) under conditions of stationary heat flow. Contact characteristics of SHS-composites were obtained on a drilling bench involving the “ring butts” loading scheme (Fig.1,
a
) (Fadin, 2011) at sliding velocity 0,5 m/s, sliding distance 5 km, mutual overlap coefficient equal 1 and with single application of a graphite grease in contact space. Contact characteristics of SHS-composites (Table 2 and Table 3) were as well examined using the “blocks-on-ring” loading condition (fig.1,
b
) on a Falex friction machine. The sliding velocity was 0.5 m/s. The sliding distance was 660 m for tests on the Falex machine. Stellite 190 served as counterbody in both schemes (Fig.1,
a-b
). Sintered composites were fabricated by fusing in vacuum at a temperature 1100
o
C during 2 hours. Contact characteristics of sintered composites at current collection sliding were determined using “block-on-shaft” testing procedure (Fig.1,
c
) under pressure 0,13 MPa. Sliding speed was 5 m/s at sliding distance 9 km without grease. Steel-45 (50 HRC) served as counterbody.
Results and Discussion
It is reasonable to start the study of external friction of new model materials from contact characteristics defining the selection of materials, which could be
 
perspective for further study and obtaining general regularities. The friction of composite TiC+50%(Ni,Cr)
 
using the “ring butts” loading scheme shows a sharp rise of friction coefficient
 f
versus the pressure growth. Simultaneously rapid deteorioration of friction surface occurs as a result of intense adhesive interaction with
 
the counterbody.
TABLE
1.
 PHYSICAL AND MECHANICAL CHARACTERISTICS OF MICROHETEROGENEOUS COMPOSITES BASED ON TIC PRODUCED BY SHS METHOD
 
Composition, vol % \ Characteristic
λ
0
, W/m·K
 HV 
, MPa
σ,
 
MPa
а
TiC
 ,
 
10
-10
 m
а
 Fe
, 10
-10
 m
а
Cu
 ,
 
10
-10
 m TiC+50%(Ni,Cr)
10 8900 1200 4,3248 - -
TiC+30%Cu+20%(Co,Ni,Cr)
22 3200 - 4,3212 - 3,5690
TiC+50%Cu
35 4230 622 4,3253 - 3,6154
TiC+30%Cu+20%Fe
44 6200 803 4,3236 2,8723 3,6154
TABLE
2.
 HARDNESS
 ,
 PHYSICAL AND CONTACT CHARACTERISTICS OF MICROHETEROGENEOUS COMPOSITES BASED ON TITANIUM CARBIDE
 
Composition, vol % \ Characteristic
 HV 
, GPa
λ
0
, W/m·K
 a
TiC
, 10
-10
m
a
Cu
, 10
-10
m
  f d
, mm
 р
, MPa
Т 
, K TiC+30%Cu+20%Fe
6,2 44 4,3236 3,6154 0,205 0,910 130 425
TiC+20%Cu+20%Fe
8,8 - 4,3265 3,6154 0,210 0,844 141 451
TiC+30%Cu+20%HS
7,85 19 4,3290 3,6429 0,176 0,938 127 429
TiC+20%Cu+20%HS
10,8 - 4,3256 3,6473 0,198 0,869 137 443
TiC+10%Cu+25%HS
12,1 - 4,3256 3,6577 0,192 0,856 139 436
 
www.seipub.org/fwr Friction and Wear Research Volume 2, 2014 24
 
TABLE
3.
 CONTACT PARAMETERS OF MACROHETEROGENEOUS SATURATED COMPOSITES
 ,
 CONTAINING COMPOSITES TIC
+10%
CU
+25%
HS AND STELLITE
190
 AS GRANULES
 Composition, vol % \ Characteristic
 f d
 , mm
 р
 , MPa
Т 
 , K [TiC+10%Cu+25%HS]+30%Fe+30%Bronze(Cu+8%Sn+12%Pb) 0,172 0,613 194 438 Stellite 190+30%Fe+30%Bronze(Cu+8%Sn+12%Pb) [Commercial
САМ
-5] 0,168 0,858 138 422
VA
21
220V
N
 
a) b) c)
FIG. 1. BASIC SCHEMES OF TRIBOLOGICAL LOADING:
 A)
 - RING BUTTS,
B)
 - BLOCKS-ON-RING,
C)
 - BLOCK-ON-SHAFT (1 – COMPOSITE SAMPLES, 2 –CONTERBODY, 3 – LUBRICANT)
Thick transfer layer forms on the counterbody surface. This fact indicates to low heat resistance of surface layer and instability of its structure. Assuming that adhesion could be reduced by temperature decreasing in friction zone, copper was injected into the composite for more efficient friction heat removal. Besides, cobalt was added to the exothermal mixture to improve the heat stability of the surface layer (SL). In this way the composite TiC+30%Cu+20%(Co,Ni,Cr) of improved heat conductivity, was manufactured and tested for friction (Table 1). As a result friction coefficient decreased (Fig. 2) but a thick transfer layer on counterbody formed due to adhesion and thus wear resistance of composite decreased. Assuming that heat stability of the SL could be increased more considerably, SHS-composite TiC+25%Co+25%Cr was fabricated. Structural state of its SL has not changed during the friction under contact pressure up to 50 MPa. However, the SL temperature was too high so that grease burned out, and quasiperiodic cracks appeared on friction surface as a result of probable excitation of friction autooscilations. These results indicate on the insufficient improvement of heat resistance. It should be mentioned that the TiC lattice parameters in these composites are almost the same values (Table 1). Hence TiC properties in different composites are the same, and difference in friction  behavior is
 
determined by the composition of metallic matrix. It is known that large plastic deformation of pure metals does not lead usually to nanostructural and amorphous state due to easy relaxation process. Intermetallic compounds could be transferred to the amorphous state due to hindrance in occurring the relaxation processes at high strains. Thus the relaxation in a zone of stress appearance is a basic factor to define the type of structure (Glezer, 2010). This indicates on the fact that the presence of elements solution or several phases in contact spot inhibits the effective relaxation of stress generated during the moment of contact.
FIG.2. FRICTION COEFFICIENT VERSUS PRESSURE ON THE WORN SURFACE OF COMPOSITES: 1 – TiC+50%(Ni-Cr), 2 – TiC+30%Cu+20%(Co,Ni-Cr), 3 – TiC+50%Cu
,
 4 – TiC+30%Cu+20%Fe, 5 – CAM-5
 
Therefore large plastic deformation at such contact spot will lead to its rapid destruction. Complex composition of contact layer or of microvolumes of contact spots could be caused by complex assortment of chemical elements or phases in initial material structure. Besides, complex composition of metallic matrix leads to low heat conductivity of a composite. This allows assuming that composites having a complex structure, complex set of chemical elements or phases in its structure are not capable of easy stress relaxation in SL and would collapse under pressure loading faster than composites with simpler structure.

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